RU2283763C2 - Mold and process for dynamic molding - Google Patents

Abstract

FIELD: dynamic molding process and equipment for performing the same.

SUBSTANCE: manufacturing process includes three or more stages (separate operations) performed simultaneously. Machine for molding by blowing and machine for molding by injection may operate simultaneously with the same mold. Dynamic molding process is realized at dividing mold by several parts. It provides movement of separate parts of mold and extracting product out of it and also step-by step realization of manufacturing process. For example, in order to satisfy demands related to process thermodynamics, to temperature range of product and lowered cost of mold design, two or more operations may be performed successively one after another at short intervals. Dynamic mold is used for working metals, for example for punching, forging, hydraulic shaping and so on. Manufacturing process may be combined with all known industrial operations for working metals, plastics, ceramic and glass, possibly in ground form. Material supply is limited only according to safety of product and production process. According to invention process needs lowered number of manual operations and equipment units. Simplified secondary processing of raw materials is safe for environment. Production of plastic containers for cold and hot drinks significantly reduces cost of plastics and cost of secondary processing of raw material as quantity of products for secondary processing decreases.

EFFECT: improved quality of products, simplified molding process for making polymeric products, easy extraction of product out of mold.

18 cl, 22 dwg

Description

Description of dynamic molding: mold and molding process

Field of Invention

This invention relates to the manufacture of plastic containers: the manufacturing process itself and the necessary technical equipment for this. The invention also relates to the processing of materials such as metal, plastic, glass, ceramics, etc. with an emphasis on the molding process and its low cost.

BACKGROUND AND DESCRIPTION OF THE INVENTION

Process

The manufacturing process of the product involves the completion of several operations simultaneously. For example, one operation is the formation of a product by injection, as a result of which a plastic cup is made. The second operation is the formation of the product by blowing, leading to the manufacture of a plastic bottle for drinks. Dynamic molding allows both operations to occur simultaneously, thus saving labor and possibly reducing the use of machines. This leads to lower prices and production times and improves product quality. However, if necessary, dynamic molding allows each operation to be performed separately. Or, two operations can occur not simultaneously and not sequentially, but with a small time gap, which is due to such aspects of production as the movement of machines and temperature conditions. Dynamic molding is compatible with all known manufacturing operations, such as gas molding or hot forming, with all metal processing and material feeding methods. It does not lead to the formation of hazardous substances such as nitrocellulose. It does not include operations that pose a danger to staff (it is safe). The supply of material does not lead to the formation of hazardous or toxic mixtures, and the final product is a non-toxic and safe substance. The manufacturing process allows two partially finished products, which ultimately form one product, to be combined by welding (for metals), assembly (for metal and plastic) or by bonding thermoplastic polymers, etc. If necessary, a heating coil can be added to provide heat welding and the formation of metal parts of the product. A process can also consist of only one operation and should not include more operations than necessary. Its advantages are in reducing to the necessary minimum the means of production and labor, and, accordingly, reducing the cost of production, increasing control over product quality.

Manufactured product

The appearance on the market of plastic cups will reduce the use of paper and polystyrene cups, since plastic cups, unlike paper cups, are heat-resistant and, unlike large polystyrene cups, retain their shape well, which reduces the likelihood of spilling hot water (or other drinks). Plastic cups will have a thickened layer of plastic at the top, middle or bottom, or small handles filled with air, as shown in the drawings. This will allow you to drink coffee, tea, hot chocolate and other drinks outside the house. The appearance of plastic cups will reduce the use of polystyrene foam cups, which are considered harmful to the environment, as well as paper cups, which are uncomfortable because they heat up quickly. As paper and foam cups disappear, demand for plastic cups will increase. This applies, in particular, to disposable plastic cups for parties, and to plastic cups with thin walls (which can then be recycled), which will be used as an example in the further description of the product.

The plastic needed to make plastic cups is usually PP (polypropylene), PE (polyethylene) or PVC (polyvinyl chloride). Polypropylene is one of the most commonly used types. When pouring hot drinks, a plastic cup will be able to maintain its shape and not be deformed. Mass production of plastic cups with thin walls and with thickenings of their individual parts for holding will reduce the cost of plastic from 30 cents per pound to 3 cents per pound. The dynamic molding process will reduce the use of labor. The result is a product with very interesting characteristics in terms of cost and ease of use, the appearance of which has long been expected. The production of plastic cups will lead to more economical use of paper, as well as the recycling of plastic containers, so plastic cups will be associated with the concept of respect for the environment. The media noted that the recycling of materials is not effective, it requires additional energy costs and therefore uneconomical. In the United States, for many years, the increase in land allotted for landfills has remained constant and equals 30 square kilometers with a constant thickness of the waste layer. Due to low demand, a machine has not yet been created that could sort different types of paper. This invention will make paper sorting easier, since it will not be necessary to take care of sorting the paper from which the paper cups are made and concentrate on sorting paper for office, school and newsprint (the more common types of paper). Glasses can be made of plastic (for both hot and cold drinks). This invention will make recycling materials more efficient, as well as reduce waste and energy consumption. Plastic containers will be used in the food industry as a wrapping material. Paper and polystyrene foam can be used for packaging semi-finished products intended for heating in microwave ovens, as well as for packaging products, such as musical instruments, etc.

Plastic cups with thickened holding parts can also be combined with other types of thermal insulation, such as air insulation or foam, and with various types of molding, such as, for example, gas molding. This should lead to more economical use of materials, good thermal insulation, low cost of production and good design. In the past, plastic cups were made with rather thin walls, due to high prices for plastic. Currently, low market prices for plastics, as well as recycling plastics, allow more plastics to be used. Hence, materials at lower prices and, accordingly, cheaper plastic recycling. One week is paper, the next is plastic. The thickened parts of the plastic cups will make the handling of the cups more convenient due to the larger surface for holding and thermal insulation (air, plastic, etc.).

The rounded end of the plastic cup in the drawings has a thickness of about 5 mm, and its walls are about 1 mm. This will make the handling of hot drinks more convenient, since the area of the holding parts is much larger than that of previously manufactured cups. Plastic prices are lower than in the past and, due to the application of the dynamic molding process, labor costs will be lower. The design of large cups is also shown in the drawings.

According to the Fourier law of thermal conductivity, the temperature distribution on the plane of the cylinder, such as a rounded end, corresponds to a logarithmic rather than linear function. The same goes for spherical surfaces. A constant heat influx has a temperature Tr (radial) = (Ts1-Ts2 / (ln (r1 / r2)) * ln (r / r2) + T2, where 2 corresponds to the medium outside the wall, and 1 corresponds to the liquid (hot deposit) in a cup (the radius is such, as indicated below). The thermal conductivity through the wall corresponds to the function of the distance from the inner wall to the outer wall. That is, the greater the distance, the lower the temperature Tx = (Ts2-Ts1) * x / 1 + Ts1, where 2 is medium outside the wall and 1 - hot cast in the cup.The temperature is higher if the distance is less or the thickness in the case of plastic cups. It allows you to cool drinks in the upper part of the cup (where their rounded end is located) faster than where the walls are flat. There are many packages in the production process, the manufacturing process of which involves two operations. This process becomes single when using dynamic molding. Making cups is also possible in the form of cubes, triangles and luxury (this is more expensive and applies to small batches of product), as shown in the drawings. Cup making is the manufacture of their various components, which are fastened together using a dynamic molding process (simultaneously or with a small gap, in two or more operations). In the manufacturing process, plastics, metals, ceramics, glass, supplied with the usual restrictions regarding the prevention of toxic substances, can be used.

The functional time of the PV of the dynamic molding process is the waiting time during the process. For example, the ram first may lower and form a product wall. Then, the second operation can occur, for example, by gas molding, using a formed wall, as shown in the drawings. PV is also due to thermodynamic characteristics, such as rollback after impact, cutting temperature, etc., and the need for product quality control. PV depends on some aspects of working with metal, hydroforming, punching, forging, casting, etc. PV also includes the time of moving parts from one operation to another.

Technical equipment - dynamic form and other tools

An unexpected result of a form consisting of several parts (individual matrices) is the easy extraction of the product from it. This allows two or more operations to be applied to the same form at a time, although performing only one operation is also possible. For example, making a plastic razor involves three operations. The first is the gas molding of a square rod handle. The second is the manufacture of the head by injection molding. The third is the welding of the head with a handle. Each operation requires the use of machines, labor and a certain time. The machine for dynamic molding will perform all three operations at the same time, as shown in the drawings. The form can also be used in operations where work is done outside of it and does not include partially or completely the movement of its parts. The machine will have a shape with a variety of characteristics, such as ejection openings, evaporation, grooves and the like, inherent in known industrial processes. These are just some of the many features that exist in the vast field of application. Technical equipment consists of a dynamic form consisting of several parts (separate matrices). These parts are driven by such technical means as air pistons, hydrolysis, servomotors, etc., which are attached to the parts of the mold and provide a dynamic molding process. The mold will have a body - a rotating body, if necessary, a control panel and other tools, such as a machine for water or gas molding or for blow molding. This will allow you to carry out several operations simultaneously or during the functional time. Technical equipment will also include sensors showing the speed of the ram and its position, instrumentation, microcomputers, computers, the Internet, a bracket, electric drives, digitally controlled devices, matrix bolts, solenoids, etc. Enumeration of all possible characteristics is not the purpose of the description of the present invention. The emphasis is on the description of the general idea of the invention, and aspects of its design may vary. Technical equipment can be implemented in new machines that comply with new technologies.

Important elements are a dynamic mold and one or more machines that perform gas blowing, injection molding, hydroforming, water molding, mold casting, and the like. for metals, plastics, etc. Two separate fixtures are dynamic shape and dynamic shape plus other tools. If they are better regarded as separate inventions, the examiner can do this.

DETAILED DESCRIPTION - Best Practices for Using the Invention

DESCRIPTION OF DRAWINGS

The first is a description of the process - the illustration shows different types of forms (dynamic).

Figure 1, operational type 1a

Parts of molds 1, 3 extend only if the part needs to be removed. First, the ram 1 is lowered, injection molding is performed, then the product 7 is formed, then gas molding is carried out by means of a plastic tube 4. Then heat welding is performed, since the wall of the product obtained after injection molding is in the gas path. The upper parts of the molds 1, 3 extend and the ejectors 5 discard the product. Part of form 2 is fixed and equipped with grooves with holes 6. There is a functional time.

Figure 2, operational type 1b

Here, everything happens the same as in 1a, only the upper part of the mold 10 does not extend when the product 11 is pushed up. In this case, the ram 9 and the ram 8 simultaneously push the product, and it is formed by injection molding. Part 10 is motionless, and yet two operations occur. The upper part 3 can be replaced by another part so as to allow two operations to proceed simultaneously in that region of the mold. For example, it could be punching and gas molding. Dynamic Form 0 is shown with variations.

Figures 3 and 4, operational type 2

The upper part is injection molded, and the lower part is blow molding. The first stage involves molding the product 16 by injection, and the ram 12 goes down. Then the ram 12 rises slightly, and the part 14 moves slightly, allowing the molding operation to be carried out by blowing 13. When it is finished, then the parts 15 and 14 are moved away, and the final product is pushed out. Part 17 remains stationary. In this case, one operation is performed first, and then the second. This is due to the characteristics of the form and the process itself. The product is created by injection molding and lowering the ram 16, plus blow molding, which leads to welding of the parts of the product obtained by injection molding and blow molding. Injection molding and lowering of the ram 16 help create a mold on the basis of which blow molding is deployed.

5, operational type 3

Here, several operations are performed simultaneously. On the first ethane, an injection molding operation 18, a gas molding operation 19, and a blow molding operation 20. The mold 26 consists of four parts: part 23 extends when the product is removed from the mold, and it works together with part 22 in the gas molding process. Part 22 moves in accordance with the operations programmed for the dynamic molding process using instrumentation programmable instruments. (Part 25 is pushers and other auxiliaries.)

A process during which several operations are performed simultaneously can be, for example, a blow process, which includes A - gas molding, B - injection molding, C - hot molding, D - something else and further other operations known today, and those that will be open in the future. The number of types of operations is unlimited (only, perhaps, for practical reasons). For example, type ABA will be gas molding, gas molding, and injection molding using a dynamic mold. The example of FIG. 5 is an ABC type. All possible types are A, B, C, AA, DC, AB, ABB, ABBA, ADGS, D, ... etc.

6, operational type 4

Two or more operations are performed with the fixed part of form 27, with rams 28 and 29. For types such as explosives.

7, operational type 5

A similar process, but one in which metals are used.

In this process, ram 30 and hydroforming 31 are used in relation to operating types 3 and 4. Part 32 extends, part 33 remains stationary.

All known manufacturing processes can be applied in the process of dynamic molding with a dynamic shape.

8, operational type 6

Here two or more operations can occur outside of the form. For example, one operation takes place inside the form, and the second outside. Operation 35 consists in drilling. Operation 34 can use both plastic and metal, as well as ceramics and glass.

Fig.9 contains an example of replacing a technical step process with a large investment of time during which a plastic razor is produced by a new method for producing razors using a dynamic molding process.

If necessary, the heating wire for welding can be used in the six previously mentioned types of operations.

The functional time of the PV associated with the production of the product, for example, with the cooling of parts, can be stretched. If the cooling of parts proceeds more slowly, the material has more time to move away and harden inside. Norms of product strength depend on the solidification process.

All (most) types of ceramics, glass, plastics, metals, etc. can be used here.

The invention is not limited to its described embodiment - the process, technical equipment, dynamic form and use together with other machines.

Technical equipment

In figure 10, the technical equipment of the dynamic mold 36 consists of machines for molding and production operations, such as hydroforming and / or injection molding 34 and 35, connected to the device for feeding material 38, with a control panel 37 and with a housing 39. The latter contains such elements such as servomotors, valves of hydraulic pumps that work in accordance with the movements of the dynamic parts of the mold, a stand or a rotating stand for a dynamic mold, and more, such as grooves, plugs, holes, solenoids, ejection her springs and bolts.

Production

11 shows a party cup with thin walls 40 and a thickened plastic part or a part with heat insulation 41. The thickness of this part is about 5 mm and the depth of the cup is about a finger (big hands). The cup wall thickness is approximately 1 mm. In today's market, the material for the manufacture will be PP ((polypropylene), PE (polyethylene) or PVC (polyvinyl chloride). Usually, this is PE (polyethylene), about 10 cm in height and 8 cm in diameter. In Fig. 12, the thickened part is at the top of the cup 42. It contributes to its elasticity and strength.

13, the thickened portion is in the middle of the cup 43.

On Fig thickened parts are at the top and bottom of the cup 44 along its entire perimeter.

In Fig. 15, the thickened part is located at the top of the cup 45 along its perimeter, and also from the side (from 2, 3 or more sides), which creates additional stability necessary for large cups.

On Fig presents various shapes of cups.

17 depicts a simple injection molding process by which a hand lever 46 is created. This lever may be located at the top or bottom of the cup. These cups are cheap to manufacture and easy to stack.

In Fig. 18, bottle 47 is created by blow molding, cup 48 is injection molded, handle 49 and cap 50 are gas molded. This is a suite of luxury products.

On Fig presents the process of metal processing, hydroforming and bending using dynamic molding.

20 is a clip 51 used to hold cups for parties or to hold plastic cups while consuming hot or cold drinks.

On Fig presents a clip with handles.

On Fig depicts a clothespin with a handle 51 for better holding and with a tight spring.

Changes in the manufacture of plastic containers, in operations, in the process of dynamic molding, in technical equipment and in dynamic form, such as described, are possible, but they should not be beyond the scope of this invention. For containers, this is their shape, material, etc.

The dynamic molding process allows two or more operations to occur simultaneously or in functional time (with a small gap).

The dynamic form has several moving, motionless and interchangeable parts. This allows the product to be freely removed. It also allows two operations to proceed simultaneously, and one of the parts of the product to participate in subsequent operations, i.e. a process with many operations is created. This concept saves time and economically use the technique.

Materials for manufacturing can be metals, plastic, ceramics, etc. Operations include all known manufacturing operations, as well as those that will appear in the future. For example, blow molding, injection molding, hydroforming, mold casting, etc.

The product is distinguished by good environmental characteristics, reduced use of labor, increased quality and the possibility of mass production. The latter proceeds using a dynamic molding process, appropriate technical equipment and with respect to the creation of the described product.

The desired technical result is achieved due to the following set of features:

A product manufacturing mold includes a plurality of interchangeable separation matrices for forming a product, in which at least two separated matrices are interconnected by a bonding means and at least one of the linked matrices is a movable matrix, moved by the technical means from the first position for the first production process to the second the position in which the movable part is stationary.

In this case, the movable part of the mold is replaceable and at least in one part there is a groove.

There is also a control lever connected to the groove, and a plug connected to the groove, allowing to stop the flow of fluid in the groove and, thus, control the fluid inside and outside the mold.

Many individual parts may contain many grooves through which fluids communicate. The mold may be connected by means of connecting parts. Motors, hydraulic means and air valves can be used to bring parts of the mold into motion.

The form can be controlled using a programming device. The programming device can determine the position of the product inside the form and its parts. Means of connecting parts of the form may be bolts.

The form includes at least one tool for forming or changing the characteristics of the product in the form, and may also have a control panel that controls, transfers information and controls all operations applied to the form during the production of the product.

The mold can be configured to work with an automated machine for manufacturing a product, which consists of a mold according to claim 1 of the invention, a rotating stand for the mold, housing, device for feeding materials, at least one tool for forming or changing the characteristics of the product, remote control, which controls, transfers information and controls all operations applied to the form, and a computer that communicates with the control panel and allows you to set the characteristics of the produced x products, track system flexibility, speed and accuracy of operations, and determine product quality.

The product manufacturing process consists of the following steps:

connection of many connecting parts of the form,

placing raw materials for the production of the product in the form,

at least one of the individual parts of the form is connected to other parts in many positions, ensuring the flow of many operations during the production of the product, the first production operation by moving parts of the form,

moving parts of the mold to their secondary position to facilitate subsequent manufacturing operations.

It also includes the use of a heating wire that helps to carry out the production process and contains the steps of:

tracking the production of the product using an external programming device;

computerization of the process, where the computer communicates with an external programming device and participates in the programming of the production process of new products, providing system flexibility, speed and accuracy of operations and adjusting product quality.

DESCRIPTION OF DRAWINGS

Figures 1-8 are cross-sectional views of a dynamic shape and other details. The mold consists of individual parts, the molding itself includes various manufacturing processes.

Fig.9 represents the present operation.

Figure 10 represents the technical equipment.

11-17 are a front view and a top view of the manufacturing process of plastic containers.

FIG. 18 represents luxury containers.

Fig.19 represents the production of metal.

Fig. 20 is a clip mounted on a cup.

Figures 21 and 22 represent a clothespin with an extended handle for holding.

Claims (18)

1. A product manufacturing mold comprising a plurality of interchangeable separating matrices for forming a product, in which at least two separated matrices are interconnected by bonding means and at least one of the linked matrices is a movable matrix moved by the technical means from the first position to the first process production to the second position in which the movable part is stationary. 2. The mold according to claim 1, characterized in that the movable part of the mold is replaceable. 3. The mold according to claim 1, characterized in that it contains at least one part in which there is a groove. 4. The form according to claim 3, characterized in that it also contains a control lever connected to the groove. 5. The mold according to claim 3, characterized in that it also contains a plug connected to the groove, allowing to stop the flow of fluid in the groove and, thus, control the fluid inside and outside the mold. 6. A mold according to any one of the preceding claims, characterized in that the plurality of individual parts comprise a plurality of grooves by which liquids communicate. 7. A mold according to any one of the preceding paragraphs, characterized in that it is connected by means of connecting parts. 8. A mold according to any one of the preceding paragraphs, characterized in that the means for bringing the parts of the mold into motion are motors, hydraulic means and air valves. 9. A form according to any one of the preceding paragraphs, characterized in that it is controlled by a programming device. 10. The form according to claim 9, characterized in that the programming device can determine the position of the product inside the form and its parts. 11. A mold according to any one of claims 7 to 10, characterized in that the means for connecting the parts are bolts. 12. The mold according to any one of the preceding paragraphs, characterized in that it includes at least one tool for shaping or changing the characteristics of the product in the mold. 13. The form according to any one of the preceding paragraphs, characterized in that it has a control panel that controls, transfers information and controls all operations applied to the form during the production of the product. 14. A mold according to any one of the preceding paragraphs, characterized in that it is configured to work with an automated machine for producing a product, which consists of a mold according to claim 1, a rotating stand for the mold, housing, device for feeding materials of at least one a tool for forming or changing product characteristics, a control panel that controls, transfers information and controls all operations applied to the form, and a computer that communicates with the control panel and allows you to set characteristics of manufactured products, track system flexibility, speed and accuracy of operation and to determine the quality of the product. 15. The production process of the product, consisting of the following steps: connecting a plurality of connecting parts of the mold, placing the raw materials for the production of the product in the mold, at least one of the individual parts of the mold is connected to other parts in many positions, ensuring the flow of many operations during production of the product, the completion of the first production operation by moving parts of the form, moving the parts of the form to their secondary position to facilitate subsequent production operations. 16. The process of manufacturing a product according to clause 15, characterized in that it also includes the use of a heating wire that helps to carry out the production process. 17. The product manufacturing process according to claim 15, characterized in that it also comprises the steps of monitoring the production of the product using an external programming device. 18. The product manufacturing process according to claim 15, characterized in that it also comprises the steps of computerizing the process, where the computer communicates with an external programming device and participates in programming the production process for new products, providing system flexibility, speed and accuracy of operations, and adjusting product quality.

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